1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Plant managers and engineering contractors consistently face critical challenges with their primary crushing stations:

Excessive Unplanned Downtime: Premature wear of critical components leads to catastrophic failure, halting the entire downstream process. Each hour of lost production can represent tens of thousands in revenue.
Unsustainably High Maintenance Costs: Frequent liner changes, extensive manual adjustments, and the laborintensive nature of traditional crusher upkeep create significant OPEX and safety exposure.
Inconsistent Throughput & Product Size: Fluctuations in feed material hardness and size cause output gradation to drift, creating bottlenecks for secondary crushers and mills, reducing overall plant efficiency.
Rising Energy Consumption: Older, inefficient drive systems consume excessive power per ton of processed material, directly impacting your bottom line amid volatile energy prices.

Is your operation equipped to overcome these challenges? The foundation of a reliable, highyield comminution circuit begins with a robust primary crushing solution engineered for maximum uptime and controlled costperton.

2. PRODUCT OVERVIEW: GYRATORY CRUSHER

A gyratory crusher is a stationary primary compression crusher, central to largescale mining and aggregate operations. It is designed for highcapacity crushing of runofmine ore or blasted rock down to a size suitable for conveyor transport and further processing.

Operational Workflow:
1. Feed Intake: Large feed material is directed into the crushing chamber from above via a feed hopper and spider assembly.
2. Compressive Crushing: The central mantle gyrates within the concave liners, applying progressive compressive force to reduce material by squeezing it against the stationary concaves.
3. Discharge: Crushed product exits through the discharge opening at the bottom of the chamber, with size determined by the closedside setting (CSS).

Application Scope & Limitations:
Scope: Ideal for very highcapacity applications (typically >1,000 tph), handling hard to mediumhard abrasive materials. It is the preferred solution for largevolume metal mines (copper, iron ore) and major aggregate quarries.
Limitations: Higher capital cost (CAPEX) compared to equivalent jaw crushers. Requires a stable, reinforced concrete foundation. Not suitable for mobile or semimobile applications where frequent relocation is needed.

3. CORE FEATURES

Patented Concave & Mantle Profiles | Technical Basis: Computeroptimized crushing chamber geometry | Operational Benefit: Delivers a consistent, wellshaped product with fewer slabby or elongated particles | ROI Impact: Reduces recirculating load and wear on downstream equipment by up to 15%, lowering systemwide energy and maintenance costs.

Integrated Automatic Setting Regulation | Technical Basis: Hydraulic adjustment system with realtime position sensors | Operational Benefit: Allows operators to adjust CSS remotely under load in minutes versus hours of manual work | ROI Impact: Minimizes noncrushing time for adjustments by over 90%, increasing annual available production hours.

Lube System with Condition Monitoring | Technical Basis: Highefficiency geardriven lubrication pump with flow/temperature/pressure sensors | Operational Benefit: Ensures optimal bearing health, prevents thermal shutdowns, and provides predictive maintenance data | ROI Impact: Extends major bearing service life; field data shows a 40% reduction in lube systemrelated failures.

TopService Design | Technical Basis: All routine maintenance tasks accessible from above via the threaded shaft hub | Operational Benefit: Enables safer, faster liner changes without personnel entering the crusher cavity from below | ROI Impact: Reduces liner changeout time by up to 50%, improving personnel safety and plant availability.

HeavyDuty Main Shaft Design | Technical Basis: Forged alloy steel shaft with precisionmachined threads for mantle attachment | Operational Benefit: Provides exceptional resistance to bending stress and fatigue under peak loads | ROI Impact: Eliminates unplanned shaft failures; documented service life exceeds 10 years in standard duty cycles.

Spiderless Design Option (for smaller models) | Technical Basis: Eliminates the traditional spider bridge frame at the feed opening | Operational Benefit: Allows easier handling of sticky feeds and simplifies maintenance access | ROI Impact: Reduces feed blockage incidents by approximately 30% in challenging claybound ores.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Availability (Annual) | 92 94% |> 96% |> +2% +4% Improvement |
| Liner Change Time (Major) | 36 48 hours| 33% Faster |
| Crushing Efficiency (kWh/tonne) Varies by material| ~0.65 0.85 kWh/t| ~0.55 0.75 kWh/t |> Up to 12% Reduction |
| Mean Time Between Failure (MTBF) Mechanical| ~6,000 hours| >8,500 hours |> ~40% Improvement |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 to over 10,000 tonnes per hour (tph), dependent on model selection and feed characteristics.
Motor Power: Standard drives from 450 kW up to 1,200 kW.
Feed Opening: Gape sizes from 1,000 mm to 1,500 mm.
Material Specifications: Main frame constructed from highstrength welded steel; Concave liners available in premium manganese steel alloys; Optional chrome white iron or composite alloys for highly abrasive applications.
Physical Dimensions & Weight: Approximate installed weight ranges from 250 tonnes to over 500 tonnes. Foundation loading forces are provided as part of project engineering documentation.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust sealing systems are standard for operation in environments with strict particulate controls.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A tier1 copper operation needed to increase plant throughput by 25%. The existing primary crusher was a bottleneck requiring excessive maintenance downtime.
Solution: Installation of a new highcapacity gyratory crusher with automated setting control as part of a new coarse ore conveying line.
Results: Achieved sustained throughput exceeding design capacity by 8%. Predictive lubrication monitoring prevented two potential unplanned outages in the first year alone.

Major Granite Aggregate Quarry

Challenge: Inconsistent product shape from an aging primary crusher led to poor performance in downstream shaping circuits and reduced premium product yield.
Solution: Replacement with a modern gyratory crusher featuring optimized chamber geometry.
Results: Product cubicity improved by over 20%, increasing saleable chip yield significantly while reducing recirculated load through secondary cones.

7. COMMERCIAL CONSIDERATIONS

Our gyratory crushers are offered across several tiers:
Standard Duty Models: For consistent feed materials in aggregate applications.
HeavyDuty Models (Most Common): For hard rock mining operations; includes enhanced wear packages.
Super Duty Models: Engineered for ultrahigh throughput or extremely abrasive ores.

Optional features include advanced condition monitoring packages (vibration analysis), automated wear compensation software integration,and custom discharge conveyor designs.

We offer comprehensive service agreements covering planned maintenance inspections,lifetime performance guarantees on key components,and guaranteed parts availability within defined response times.Financing options including leasetoown structuresand projectbased capital expenditure plans are available through our commercial partners.

8.FAQ

Q:What are my options if my feed contains significant clay or moisture?
A:A spiderless design combined with specific concave profiles can be specified.This configuration minimizes material bridging at the intake,a common issue with sticky feeds.Field data shows this reduces cleaningrelated downtime substantially

.Q.How does automation integration work?
A Our crushers come PLCreadywith standard interfaces(420mA,Ethernet/IP)for full integration into your plant SCADA system.Automatic setting regulationand lubrication control can be managed remotely

.Q.What is your approachto spare parts supply?
A We maintain strategic global inventory hubs.Guaranteed parts availability programs ensure critical components like main shaft assembliesor top shellsare availablefor shipment within agreedupon timeframes,supportedby performancebased logistics contracts

.Q.Can you assistwith foundation designand installation?
A Yes.We provide complete installation drawingsincluding dynamic load dataand offer supervised installation services conductedby our certified field engineers.This ensures correct commissioningand validates warranty conditions

.Q.What financing structuresare typicalfor equipmentof this scale?
A Transactions often involve progress payment schedules tiedto manufacturing milestonesor project finance solutions.We workwith financial institutionsto provide lease arrangements that preserve capitalor traditional term loans